Flashlight reflector assembly for prefocused lamp mounting



Sept. 28, 1954 E. J. FLASHLIGHT REFLECTOR ASSEMBLY FOR PREFOCUSED LAMPMOUNTING Filed March 28, 1952 GARLAN D 2,690,503

EdwarJclGarlan/cl Patented Sept. 28, 1954 FLASHLIGHT' REFLECTOR ASSEMBLYFOR PREFOCUSED LAMP MOUNTING Edward J. Garland, Shrewsbury, Mass.,assignor to Ray-O-Vac Company, Madison, Wis., a corporation of WisconsinApplication March 28, 1952, Serial No. 279,090

11 Claims.

My invention relates to improvements in a flashlight and, moreparticularly, to the reflector assembly for a pre-focused type lampmounting.

The principal object of my invention is to provide an assemblyconsisting of a molded electrically non-conductive reflector body and ametallic socket for receiving a pre-focused type lamp wherein thereflector body has metallic reflective coating deposited on its frontface and an electrical conductive material positioned on its rear facein electrically conductive contact with the metallic socket.

A further object of my invention is to provide a flash-light reflectorassembly for mounting a pre-focused type lamp which is easilymanufactured, is relatively inexpensive and yet furnishes a permanenthighly reflective surface for a prefocused type lamp.

A still further object of my invention is to provide a molded reflectorof electrically nonconductive material having an outwardly extendingbead at its front end so that it may be secured in the end of aflashlight case, an integrally molded apcrtured neck at its center whichhas secured therein a tubular metallic socket formed with a seatingflange for a pre-focuscdtype lamp and having threads formed in the wallsthereof to receive a lamp securing plug while the front face of thereflector has deposited thereon a permanent highly reflective coatingand the rear face of the reflector has fitted thereagainst a conductiveconcave-like element which is provided with a centrally apertured sleevepress fitted over the socket and in electrical contact therewith.

Still further objects and the entire scope of applicability of thepresent invention wi-lf become apparent from the detaileddescriptiongiven hereinafter; it should be understood, however, that. the detaileddescription and specific examples are given by way of illustration onlyand, while indicating preferred, embodiments of. the invention, are notgiven by way of limitation, since various changes and modificationswithin the spirit and scope of the invention will become apparent tothose skilled in the art from this detailed description.

For a. more complete understanding of. the nature and scope of theinvention, reference may be had to the following, description anddrawings in which:

Fig. l is a cross sectional view of the forward half of a flashlightshowing the mounting of the reflector assembly, pre-focusedtype lamp,batteries, and electrical contact from the switch to the. conductiverear surface of the reflector and thence to the lamp;

Fig. 2 is a side elevation partially in sectionv of one: form of thereflector assembly as depicted in the flashlight in Fig. 1;

Fig. 3 is an. enlarged cross-sectional view along section line 3-3 inFig. 2;

Fig. 4 is a side elevation of the metallic socket of the reflectorassembly;

Fig; 5 is a side elevation partially section of a modified form ofreflector assembly showing a conductive coating on the. rear side of thereflector body; and

Fig. 6. is a cross sectional section line [i-6 in Fig. 1.

Throughout the various. figures of the drawings like reference numeralsrefer to similar parts.

Referring to Fig. 1, a typical flashlight case, herein illustrated as ofnon-conductive material, is indicated generally at I 0 and is provided.with an outwardly tapered front end: I l having a shouldered recess 12-formed in the end thereof which is threaded as indicated at l3 toreceive a lens l4. Lens [4 is provided with a rearwardly extendingannular shoulder l5 that is externally threaded at I5 so that it may bepositioned by means of threads [3 in recess l2. It will be understoodthat the foregoing description of the flashlight head is forillustration only and that various arrangements, known to the art, maybe employed for positioning and securing the reflector.

A reflector assembly, according to my invention, is generally indicatedat l6 and is provided with a molded on head I! which extends outwardlyat the front end of the reflector and transverse to the longitudinalaxis Y-Y" through the center of the reflector. This bead I! fits withinthe shoulder l2 and has the annular shoulder l5 of the lens I4 screwedthereagainst so as tohold the reflector in mounted position in the endll of the flashlight. Here again it should be understood that the shapeof the outer flared end of the reflector has been adapted to theillustrative form of flashlight headthe shape of this outer end of thereflector may be changed to cooperate With other forms of flashlightbeads.

In Fig. 2 the reflector assembly 16 is shown in somewhat enlarged form.Th body [8 of the reflector is of electrically non-conducting readilymolded plastic material, such as styrene, which may be suitably shapedin an injection mold. It is desirable to mold the body under conditionswhich provides for a very smooth surface plan as viewed along forreceiving a metallic reflective coating. The body it is formed with aconcave front end or face 19 which terminates in an inwardly andrearwardly tapered throat portion l9 while its front end is formed withthe head i? as previously described. The rear face 28 is convex in shapeand somewhat complementary in shap to the front face 59. The extremerear end is formed as a rearwardly projecting neck 2! which is aperturedat El to receive a metallic tubular socket generally indicated at 22.The longitudinal axes of the socket 22 and the neck portion 2| coincidewith the longitudinal axis YY of the reflector.

Reflector body It has its front face or end It coated with a permanenthighly reflective metallic coating preferably aluminum whichpreferably'is deposited while in vaporized condition as by means of ahigh vacuum depositing process. The front face surfaces is and itprovide a highly'reflective area for light emanating from thepre-focused type lamp generally indicated at 23 inFig. 1.

The metallic socket 22 is of tubular shape and is formed with aninwardly extending flange 25 at its forward end to provide a seat forthe flange 23' on the pre focused type lamp 23 which also has thecustomary cylindrical shaped shank 23". Socket 22 is formed with one ormore outwardly extending annular ribs 25, see Fig. 4, which may beprovided with a knurled outer surface 25' to afford a more securegripping action in the molded neck 2i as shown thereabout in Fig. 2. Thesocket 22 has a rearwardly extending skirt portion 25 which projectsfrom the end Of the neck iii of the reflector body. This skirt portionhas threads 2'? formed in its wall and particularly on the inner surfaceto receive a screw plug 2s as shown in Fig. 1. The screw threads 2'! mayextend through substantially the whole length of the socket so that thethreads thus formed proximal to the flanged end 243 will serve as andreplace rib 25. I prefer, however, to use rib 25 as shown in Figures 2and 4 to more positively secure the socket 22 within the molded neck 2|and minimize detachment from turning.

Referring to Fig. 1, there is shown the screw plu 25, by way of example,that holds the prefocused type lamp 23 in operating position in thereflector assembly. Plug 28 may be molded of suitable plasticnon-conductive material and is formed with a longitudinal aperture 29 extending therethrough which is in spaced relationship about the shank 23"of the lamp 23. The forward end portion 30 of th plug 28 is formed as areduced annular portion so as to flt within the surrounding socket 222and still have its forward end pressed against the flange 23 on the lamp23 to hold it in operative position. Adjacent this reduced end portion33 is a slightly enlarged annular portion 3! which is formed withthreads 32 on its outer surface so as to be received within the threads21 in the socket 22. The rear end of the plug 23 is further enlarged at33 and may be provided with a knurled surface or ribs (not illustrated)so that it may be more easily grasped in the fingers and screwed intoassembled position. Plug 23 is formed with an end wall M which isapertured in its center to receive a conductive apertured rivet 35 whichis secured therein as by crimping each end against the surrounding endwall surface. This rivet 35 is in electrical contact with the endterminal post 3%; of the battery 3i. In electrical contact. with therivet 35 and housed within the elongated chamber 29 in the plug 28 is acoiled spring 38, see Figures 1 and 6. Each end of coiled spring 36extends helically and a small coil is formed at each end, one of whichis in contact with the rivet 35 While the other is in contact with theterminal 23 on the rear end of lamp 23.

In Fig. 1 there is shown in a typical flashlight, a switch 39 which isslidably mounted in the aperture ill formed in the Wall of theflashlight it. The slide switch 3% has attached an insulated operatortil which slides on the outside of the flashlight casing. Slide switch3% has a rearwardly extending conductive portion at which extends so asto make contact with the back end of the rearmost battery (not shown)while the forwardly extending conductive end 3" of the slide switch isshown in contact with the conductive means, to be described, on the rearof the reflector.

In the two types of reflectors shown, one type in Figures 1 and 2 andanother type in Fig. 5, the construction may be identical except for theconductive means at the rear of the reflector.

In Figures 1 and 2 the conductive means con sists of a metallic concave,dish-like, element d2 of brass or other metal having a shape which iscomplementar to all or a selected part of the rear surface Or face 2c ofthe reflector body is. The element 42 may cover the entire rear surface26 but a saving of metal may be effected by partial coverage and asshown in Fig. 2 extends forwardly to :33 where its edge is in spacedrelationship to the end of the reflector it. It is only necessary thatthe element d2 project forwardly a sufficient amount so as to provide aconductive contact for the end 39" of the sliding switch member 39. Therear end of the element is is apertured to be received over the neck 2ias at 3 and at 44 so as to fit over and be in contact with the skirtportion 2c of the metallic socket 22. This metallic conductiv element 42s press fitted against the rear surface or face 26 or the reflector bodyl8 and against the neck portion 2! and the skirt portion 26 of thesocket 22. Element 1 2 therefor serves the multiple functions ofproviding a conductive path between switch member 39 and sleeve 22 andalso a strengthening backing for the reflector assembly.

In the modified type of reflector l6 shown in Fig. 5 all of the partsare similar to the reflector shown and described in Figures 1 and 2,except for the conductive means on the rear of the reflector body l8. Itwill be noted here that the rear face or surface 19 of the reflectorbody I8 is coated with a conductive coating 46 which may be metalsprayed on while in molten condition. This coating 46 is extended tocover also a portion of the skirt 26 of the metallic socket 22 so thatan electrical conductive path is provided over all areas on the rear I!)of the reflector l8 and the junction thereof with the metallic socket.

The electrical conductive nature of the element 42 and the coating 46permits a circuit to be completed from the base terminal of the battery31 to the switch contact 39", thence through the metallic socket 22, andthrough the flange 23 of the lamp 23 which is seated against the flange24 on the socket 22. The other circuit from the battery electrode orpost 36 is through the rivet 35 and spring 38 to the terminal 23", onthe rear end of the lamp 23.

Either of the types of reflector assemblies shown in Figures 2 and 5provide for a very efflcientv flashlight reflector which is easilymanufactured and; at a relatively low cost.

In the. foregoing description references have been made to the variouselements of the flashused to illustrate the environment of thereflector: and assembly which comprises the present invention. It willbe understood that the details of. the flashlight casing are not part ofor limitations on, the present, invention. The flashlight casing may beof any desired shape or size, may be constructed of conductive ornonconductive materials, and may be provided with any desired type ofswitch employing either a stationary or movable contact strip.Obviously, the socket member 22 will be so positioned within the neck 21of the reflectoras to locate the flashlight bulb in the desired focalpoint, with regard to the parabolic reflecting surface: of thereflector, Metal socket member 22 may be inserted inneck 2| in theplastic reflector after the latter has been preformed, as by softeningthe neck, or may be inserted in other manners. The preferred manner ofpositioning socket 22 is by insertion thereof in the mold and moldingthe reflector and neck 2| with the socket in situ.

Since it is obvious that certain further changes can be made in theforegoing constructions without departing from the spirit and scope ofthis invention, it is intended that all matter shown in the accompanyingdrawings or described here-- inbefore shall be interpreted asillustrative and not in a limiting sense.

I claim as my invention:

1. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face:

of the reflector being concave and provided. with a metallic reflectingcoating, the rear end of the reflector having an integrally moldedrearwardly projecting neck provided with an aperture therethrough withthe longitudinal. axis thereof coinciding with the longitudinal axis ofthe reflector, a tubular metallic socket secured within said aperturedneck and having a skirt portion projecting rearwardly' beyond said neck,said socket having a transverse inwardly extending flange at its forwardend adapted to create a seat for the flange of a pro-focused type lampand threads formed in the wall of said socket, said reflector havingelectricalconductive means on the surface of the rear side which is inelectrical contact with said metallic socket, said reflector assemblybeing adapted for use with a tubular plug having a central apertureadapted to be received over the shank of a pre-focused type lamp, areduced diameter end portion adapted to seat against and hold the flangeof a prefocused type lamp against said socket flange and a threadedportion of larger diameter than said end portion adapted to be threadedinto said threads in said socket.

2. In a flashlight as described in claim 1 wherein the extreme forwardend of the reflector is molded with a bead extending outwardly andtransverse to the longitudinal axis through the center of saidreflector.

3. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflecting coating, the rear end of the reflector havingan integrally molded rearwardly projecting neck provided with anaperture therethrough having its longitudinal axis coinciding with thelongitudinal axis of the reflector, a tubular metallic socket securedwithin said apertured neck and having a skirt portion projectingrearwardly beyond said neck, said socket having a transverse inwardlyextending flange at its forward end adapted to create a seat for theflange of a pre-focused type lamp, an outwardly extending rib in thetubular wall proximal toits flanged end to assist in anchoringthesocket. in the tubular neck and threads formed in the skirt portionof the socket, said reflector having; electrical conductive means on thesurface of the rear side thereof which is in electrical contact withsaid metallic socket, said reflector assembly being adapted for use witha tubular plug having, a central aperture adapted to be received overthe shank of a pre-focused type lamp, a reduced diameter end portionadapted to seat against and. hold the flange of a pro-focused type lampagainst said socket flange and a threaded portion of larger diameterthan said end portion adapted to be threaded into said threads in saidsocket.

4. In a flashlight as described in claim 3 wherein the extreme forwardend of the reflector is molded with a bead extending outwardly andtransverseto the longitudinal axis through the center of said reflector.

5. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflecting coating deposited thereon, the rear end ofthe reflector having an integrally molded rearwardly projecting neckprovided with an aperture therethrough with the longitudinal axisthereof coinciding with the longitudinal axis of the reflector, atubular metallic socket secured within said apertured neck and having askirt portion, projecting rearwardly beyond said neck, said sockethaving a transverse inwardly extending flange at its forward end adaptedto create a seat for the flange of a pre-focused type lamp and threadsformed in the wall of said socket, said reflector having an electricalconductive coating deposited on the surface of the rear side thereof, onsaid neck and on said metallic socket to provide for electricalconduction, said reflector assembly being adapted for use with a tubularplugv having a central aperture adapted to be re ceived over the shankof a pre-focused type lamp, a reduced diameter end portion adapted toseat against and hold the flange of a pro-focused type lamp against saidsocket flange and a threaded portion of larger diameter than said. endportion adapted to be threaded into said threads in said socket.

6. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflecting coating deposited thereon, the rear end ofthe reflector having an integrally molded rearwardly projecting neckprovided with an aperture therethrough with the longitudinal axisthereof coinciding with the longitudinal axis of the reflector, atubular metallic socket secured within said apertured neck and having a,skirt portion projecting rearwardly beyond said neck, said socket havinga transversely inwardly extending flange at its forward end adapted tocreate a seat for the flange of a pre-focused type lamp and threadsformed in the wall of said socket, a concave shaped metallic elementhaving an apertured neck adapted to flt over the neck on said reflector,press fitted over at least part of the rear of said reflector and theneck of the reflector and in electrical contact with the skirt of saidsocket, said concave shaped metallic element being at least socoextensive with the rear side of said reflector as to provide a surfacefor engagement with a switch arm of a flashlight said reflector assemblybeing adapted for use with a tubular plug having a central apertureadapted to be received over the shank of a pre-focused type lamp, areduced diameter end portion adapted to seat against and hold the flangeof a pre-focused type lamp against said socket flange and a threadedportion of larger diameter than said end portion adapted to be threadedinto said thread in said socket.

7. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflective coating, the rear end of the reflector havingan integrally molded rearwardly projecting neck provided with anaperture therethrough with the longitudinal axis thereof coinciding withthe longitudinal axis of the reflector, and a tubular metallic socketsecured within said apertured neck and having a skirt portion projectingrearwardly beyond said neck, said socket having a transverse inwardlyextending flange at its forward end adapted to create a seat for theflange of a pre-focused type lamp, an outwardly extending rib in thetubular wall proximal to its flanged end to assist in anchoring thesocket in the tubular neck and threads formed in the skirt portion ofthe socket, said reflector having electrical conductive means on thesurface of the rear side thereof which is in electrical contact withsaid metallic socket to provide for electrical conduction from the rearside of the reflector to said metallic socket.

8. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflective coating, the rear end of the reflector havingan integrally molded rearwardly projecting neck provided with anaperture therethrough with the longitudinal axis thereof coinciding withthe longitudinal axis of the reflector, a tubular metallic socketsecured within said apertured neck and having a skirt portion projectingrearwardly beyond said neck, said socket having a transverse inwardlyextending flange at its forward end adapted to create a seat for theflange of a pre-focused type lamp, an outwardly extending rib in thetubular wall proximal to its flanged end to assist in anchoring thesocket in the tubular neck and threads formed in the skirt portion ofthe socket, and an electrical conductive coating deposited on thesurface of the rear side of the reflector, on said neck and on saidmetallic socket to provide for electrical conduction from the rear sideof the reflector to said metallic socket.

9. In a flashlight as described in claim 'I wherein the extreme forwardend of the reflector is molded with a bead extending outwardly andtransverse to the longitudinal axis through the center of saidreflector.

10. In a flashlight, the combination of a molded reflector of insulatingmaterial, the forward face of the reflector being concave and providedwith a metallic reflecting coating, the rear end of the reflector havingan integrally molded rearwardly projecting neck provided with anaperture therethrough with the longitudinal axis thereof coinciding withthe longitudinal axis of the reflector, a tubular metallic socketsecured within said aperture neck and having a skirt portion projectingrearwardly beyond said neck, said socket having a transverse inwardlyextending flange at its forward end adapted to create a seat for theflange of a pre-focused type lamp, an outwardly extending rib in thetubular wall proximal to its flanged end to assist in anchoring thesocket in the tubular neck and threads formed in the skirt portion ofthe socket, and a concave shaped metallic element having an aperturedneck adapted to fit over the neck on said reflector, press fitted overthe rear of said reflector, the neck of the reflector and in electricalcontact with the skirt of said socket, said concave shaped metallicelement extending forward along the rear side of said reflector to whereit is in spaced relationship to the extreme front end of said reflectorto provide for electrical conduction from the rear side of the reflectorto said metallic socket.

11. In a flashlight as described in claim 10 wherein the extreme forwardend of the reflector is molded with a bead extending outwardly andtransverse to the longitudinal axis through the center of saidreflector.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 2,100,984 Smally Nov. 30, 1937 2,231,382 Desimone Feb. 11,1941 2,326,607 Bohner Aug. 10, 1943 2,518,437 Amstutz Aug. 15, 19502,597,565 Chandler et al May 20, 1952 2,605,316 Grimsley July 29, 1952

